Charge air inter cooler used to cool charging air coming from compressor unit of Turbo Charger.Charge air coolers are located between the turbo charger and the engine air inlet manifold. When the air is compressed by the turbocharger or supercharger, it is also heated, which causes its density to decrease.

Charge air cooler (MAN B&W Engine)

Cooling the combustion air by a charge air cooler prior to sending it into the engine, the density of the air increases which permits more air to enter the engine and increases the power and efficiency of the engine..For proper combustion of fuel,it is required to maintain charge air temperature to a certain limit.(For MAN B&W 9L 58/64 engine the range is 45-55 degree Celsius).

How it works?

Hot air coming from the turbocharger(compressor unit) flows through air passage inside the intercooler. The turbocharger air transfers heat to the tubes, warming the tubes and cooling the turbo air. Outside water passes over the tubes. Heat is transferred from the hot air to cool water occurs. This is how the turbocharger air is cooled down.

The theoretical heat transfer occur

The amount of heat transfer occur between two fluids(air and water) can be calculated from the following equation,
Q = m x Cp x dT

Q =is the energy transferred.m= is the mass flowrate (lbs/minute) of fluidCp =is the heat capacity of the air. It is about 0.25 for air and 1.0 for water. .dT= is the difference in temperature between the inlet and outlet.

Intercooler Materials Tube

Tube

Aluminium (Light Weight)

Aluminum-Brass alloy

Copper

Nikel

Mild steel(cheap)

Stainless steel (heavy duty)

Aluminium tube with Zinc Sprayed(corrosion resistant)

Fin

Fin

Usually Aluminium(temperatures lower than 150°C)

Aluminium alloy

Copper( for over 150°C charge air temperature)

Tin Plated Copper( for over 150°C charge air temperature)

Frame

For applications, carbon steel and Rolled Naval Brass are widely used materials for side panels and middle mirrors respectively. Stainless steel can also be used for applications if desired. The construction must be well designed for the robustness and resistance to vibration of the unit.

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